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ENGINELIFE NEWS
TRENDS TECHNOLOGIES JOB CORNER QUICK NEWSINNOVATIONS CUSTOMER’S VIEWPOINT
, 2016
08
AIRCRAFT ENGINES
ENGINELIFE® NEWSJuly
July 2016 // 08
Despite the recent drop in the price of oil, fuel consumption is still a major challenge for airlines. Safran Aircraft Engines’ SFCO®2 service, designed to reduce this cost line by 1 to 5% a year, has already won over Ethiopian Airlines.
25 to 30% - that’s the share of fuel in airlines’ overall operating costs. This figure has seen a mathematical drop in recent months, as jet fuel prices have spiraled down. But airlines are still on the lookout for any way to limit these costs. As Jean-Thomas Rey, services marketing manager at Safran Aircraft Engines, explains, “By reducing this expense, airlines increase earnings that can be spent on new airplanes. However, some carriers are predicting that oil prices will climb back up, so they’re setting up fuel savings programs. And no matter how much a barrel of oil costs, fuel consumption is directly linked to CO2 emissions, which is another good reason to limit fuel burn.”
ENERGY AND ENVIRONMENT:A TOTAL APPROACH
TRENDS
ENGINELIFE NEWS
1
5%
30%25 to
1 to
* Développés et commercialisés par CFM International,
société 50/50 de Safran Aircraft Engines et GE.
kilo of fuel burned= 3.15 kg of CO2 emitted (7 lb)
the share of fuel in anairline’s operating costs.
reduction in the annual fuel bill, pthanks to SFCO®
2 services
July 2016 // 08
Custom-tailored support
Ethiopian Airlines has found a solution to this dual economic and environmental challenge: SFCO®2. This new service, developed jointly by Safran Aircraft Engines and Safran Electronics & Defense is based on optimizing flight operations and deploying best practices. “By combining our expertise as engine OEM with Safran Electronics & Defense’s proven skills in flight data analysis, we offer customers a comprehensive solution that accounts for all potential savings, including fuel and maintenance costs, and more,” explains Max Moutoussamy, seasoned pilot and head of the SFCO®2 program at Safran Aircraft Engines.
Pilots
The contract with Ethiopian Airlines, signed in May 2016, provides for an initial evaluation phase to collect all the data concerning fuel consumption. “Some 70 to 80 percent of the best practices we recommend are related to how pilots operate their aircraft,” notes Max Moutoussamy. “But we integrate other factors as well, including actions by ground and flight crews and maintenance procedures.” We then deliver personalized recommendations to the airline, which can measure its progress and identify remaining potential savings using a special Web-based application. Ethiopian Airlines already operates 787s and has ordered A350s, along with 737 MAX twinjets powered by the LEAP-1B engine. With these newgeneration planes, Ethiopian is clearly staking out a position as a thoroughly modern carrier that wants to cut fuel use. And the contract we signed with them is obviously in line with this commitment.”
ENGINELIFE NEWS
With new engines come new trainings… In preparation for the service entry of the LEAP engine, Safran Aircraft Engines’ Customer Training Center (CTC) has totally revamped its teaching approach and tools.
Augmented reality, simulators, 3D virtual engines… The Customer Training Center (CTC) in Montereau, near Paris, is deploying “Training 2.0” to gear up for the advent of new engines and address our customers’ changing needs. The focus is of course on digital technology, with state-of-the-art connected devices such as interactive whiteboards, tablets, etc. These devices stimulate communication between the instructor and students, since they can be used to zoom in on a specific area, annotate training materials, personalize exercises, etc. “We have a two-pronged objective,” says Pascal Retif, head of the CTC, “to emphasize the acquisition of skills rather than transmitting knowledge, and to improve retention rates.” Teaching methods have also changed, with approaches such as “blended learning”, where the method changes every half hour to keep students alert.
WELCOME TO TRAINING 2.0
INNOVATIONS
July 2016 // 08
International deployment
These tools have been operational since April 2016, right on time to start training the launch customers for the LEAP-1A-powered A320neo. Different learning modules for the three versions of LEAP will be gradually rolled out for use at all CFM training centers: at GE in Cincinnati, at CFMAESSA in Hyderabad, India, and eventually in China. “The next step is the opening in 2017 of a learning management system platform,” explains Caroline Tirel, Support team manager at CTC. “It will give our customers access to our training catalog, and let them register online, as well as using e-learning modules to learn at their own pace and test their knowledge, or even define customized training programs.”
ENGINELIFE NEWS
Digital devices stimulate communication between the instructor and students.
July 2016 // 08
The first LEAP-1A engines will be starting revenue service this summer. SSB, a Safran Aircraft Engines shop located at the Zaventem-Brussels Airport, will be ready to give airlines all the maintenance, repair and overhaul (MRO) services they need.
After a stringent qualification process, SSB is going to be the first shop accredited to service the LEAP-1A engine in Safran Aircraft Engines’ geographic zone. The company has the same scope of action as on the CFM56, for which it performs MRO services, as well as combustor maintenance and repairs. “We’re ready to offer our customers a complete solution, including shop visits,” says Bruno Michel, General Manager of SSB. “But we can also provide more limited services on engines that have been removed, called quick turns in our jargon.”
Everything needed
SSB had to work for nearly two years to get ready for the LEAP-1A, including a site reorganization, installation of a dedicated maintenance line, the acquisition of the necessary tools, a redefinition of MRO processes and investment in machinery and
BRUSSELS READY FOR THE LEAP-1A
TECHNOLOGIES
ENGINELIFE NEWS
equipment adapted to the size and materials of the new engine (composite fan blades and case, titaniumaluminide low-pressure turbine blades, etc.). As the engine gears up for service entry, several operators have undergone training at both Safran Aircraft Engines and GE facilities to handle the modules under their responsibility. “We’re gradually ramping up our capabilities so our mechanics are ready to handle both engine families, CFM56 and LEAP,” says Bruno Michel. SSB will be the core LEAP-1A support shop for Safran Aircraft Engines, then share its expertise with other shops in the network starting in 2018-2019.
“ We’re graduallyramping up our capabilities
so our mechanics are ready to handle both engine families,
CFM56 and LEAP.
“
July 2016 // 08
Every year Safran Aircraft Engines’ fan blade repair unit repairs some 12,000 blades, while delivering impeccable quality, a quick response and flawless customer support. Here we take a closer look at the keys to top quality and fast turnaround times (TAT).
The fan blade repair unit is located at our Saint-Quentin- en- Yvelines plant in the Paris suburbs, dedicated to the maintenance of commercial engines. It handles repair blades for all versions of the CFM56 and is gearing up for the service entry of the new LEAP engine. “We mainly work for shops in the Safran Aircraft Engines MRO network, thirdparty shops and directly for airlines, such as Air France, TAP Portugal and Turkish Airlines,” explains Olivier Lagier, head of the unit. There are about 60 permanent employees, spanning operators, inspectors, technical support, and sales and administrative staff.
This work demands state-of-theart skills in several areas, including thermal projection, welding, fitting, stripping, etc.
FAN BLADE REPAIR: COMBINING QUALITY AND TAT
JOB CORNER
ENGINELIFE NEWS
Customers first!
The fan blade repair unit recently conducted a transformation initiative based on Lean-Sigma precepts, now the industry benchmark, to maximize customer satisfaction. “We invested in new repair machinery, changed our batch sizes, introduced training plans and reorganized our management approach to enhance efficiency,” says Olivier Lagier. “That shortened our cycles by over 30 percent, placing us on a par with the world leaders in terms of turnaround time, or TAT. Furthermore, our close collaboration with Safran Aircraft Engines’ design department helps us post the lowest scrap rates in the industry, a guarantee of substantial savings for our customers.” Over and above these improvements, quality is still the unit’s top priority.
It also offers customers standard replacements, of course, and very responsive technical support. “We’re fully prepared to support our customers with world-class performance in terms of quality, cost, deadlines and service”, notes Olivier Lagier.
Olivier Lagier, head of the fan blade repair unit.
July 2016 // 08
You renewed your contract with Safran Aircraft Engines’ fan blade repair unit for three years in 2015 – what convinced you?
The unit is our legacy subcontractor for CFM56-5A, -5B and -5C engines, and we’re very satisfied with the relationship we’ve built up over the years. In addition to meeting all contractual performance specifications for these repairs, the unit has also demonstrated its ability to very quickly provide standard exchange for fan blades sets, and they also deliver excellent customer support. Furthermore, because we’re located very close to each other, there’s a daily shuttle, even further increasing their responsiveness when needed.
Those are the factors that influenced our decision last year.
Elodie Reytérou,Low-pressure module logistics manager, Air France Industries
CUSTOMER’S VIEWPOINT
ENGINELIFE NEWS
What changes have you noticed following the unit’s transformation?
For fan blades sets, I’ve seen a TAT reduction of two days for the -5A and -5C, and about ten days for the -5B. The size of my spare parts inventories is determined by suppliers’ turn times, so that allowed me to keep the same level of stocks, while the fleet under management was growing.
How do you see the next step in your collaboration?
We’re satisfied with the unit’s performance, availability and responsiveness, so there’s no reason not to continue working together. We haven’t transitioned to the LEAP yet, but when the time comes, naturally we’ll be talking to Safran Aircraft Engines.
July 2016 // 08
Safran Aircraft Engines and Air France Industries KLM Engineering & Maintenance (Air France KLM group) have signed a Memorandum of Understanding concerning the creation of a joint venture dedicated to the repair of blades on aircraft engine high pressure compressors. The new company’s scope of business will encompass the CFM56, GE90 and GP7200 engines. The company itself will be located near Valenciennes in northern France, and operations will kick off in 2018, significantly growing Safran’s repair capabilities on the core section of aircraft engines.
Towards a joint repair company with AFI KLM E&M
QUICK NEWS
A repair process at Châtellerault plant.
ENGINELIFE NEWS
Training Center trains on-site maintenance teams at LEAP plant LSafran Aircraft Engines’ Training Center provided training for the company’s EMOS (Engine Maintenance On Site) technicians, giving them access to a real LEAP-1A engine so they could practice the operations they will be handling daily. Based in France and international markets, EMOS teams provide local technical assistance in case of emergencies (both on-wing and off-wing engine servicing), and for scheduled maintenance (replacing life-limited parts, for instance). They will be ready to jump into action as soon as the first engine enter service.
Pascal Rétif, Customer training center manager // [email protected]
CONTACT
July 2016 // 08
Customer training on the LEAP-1A engine has already kicked off at Safran Aircraft Engines’ Customer Training Center (CTC): representatives of Turkish carrier Pegasus took an initial training course in April called, “Powerplant Line and Base Maintenance LEAP”. The CTC has also trained crews from the Scandinavian airline SAS, as well as the leasing company SES. Pegasus and SAS are among the first airlines to welcome the LEAP-1A-powered A320neo into their fleets.
Safran and French startup Safety Line have signed a Memorandum of Understanding to group their expertise and technologies to help airlines. Safety Line’s innovative OptiClimb solution will be folded into Safran’s SFCO®2 service. This comprehensive solution allows airlines to reduce their fuel consumption up to 8%. On a fleet of 20 single-aisle commercial jets, for instance, flying 3,500 hours/year on average, that represents annual savings of $6 million, and reduces CO2 emissions by over 42 tons.
First airlines trained on the LEAP-1A
Safran’s enriches core expertisewith OptiClimb
ENGINELIFE NEWS
Meet our teams at these upcoming eventsDIARY
Farnborough International Airshow July 11-15, Farnborough
IATA ACC conference August 30-31, Geneva
IATA MCC conference September 14-15, Bangkok
Aero Engines Europe conference September 14-15, Lisbon
MRO Asia September 27-29, Singapore
MRO Europe October 18-20, Amsterdam
MRO OPS IT Asia October 26-27, Bangkok
Publication director: Nathalie Lankry-ParientéEditorial committee: Pierre Schroer, Salomon Serfaty, Jean-Thomas Rey, Philippe Alassoeur, Isabelle Pierrat, Nathalie Delangue, Magali Hermet, Pascal PiveteauEditor-in-chief: Jean-Pierre AlesiDesign: Ghislaine PlougastelEditor: Alexia AttaliPhotos: E. Drouin/Safran ; Capa, DRLegal registration: July 2016ISSN No.: 2428-8004
